fla

Creative solution, good stuff.

Many thanks 👍🏾

Is it viewable anywhere yet?

Thanks. Yes, tried that, didn't seem to affect anything. I then opened it again leaving the matrix in place and it looks like the top lip of the matrix is marginally too wide by the inlet and outlet pipes. Literally half a mm. This part then doesn't sit flush on the housing, but i just cant see where its getting stuck. It sticks out by 2-3mm. Maybe I'm just making a big deal out of nothing..

i used some damplifier on the directional flap as the holes were large and the felt just didnt feel strong enough. I had some thick black felt from some years back, but not enough for anything other than the hot/cold diverter and a portion of the black plastic flap. Need to clean up the outside now and replace the remaining flaky foam gaskets Anyway, interested in any advice regarding the seating of the matrix

all cleaned up and refelted nicely. Problem is that the heater matrix doesnt go down fully, its about 2mm proud of the slot. Tried taking it out and using the old plastic cover at the bottom which looks to be about 1-2mm shorter, but still no luck. I've pivotted it and moved it around slightly but it still seems to stop without one side sitting properly. This is a Mahle matrix. Anyone else had this problem, and if so how did you solve it? I was thinking of just putting some butyl rope along the top - to be honest i dont think it will make much difference but i'd rather fit it properly if i can. Thanks Hasan

well done! I've managed to separate most of them, its the one on the inside thats stuck and i cant really pull the two sides apart. What a dumb clip design though!

I bought a new matrix from Mahle, seems quite well made but didnt have the foam gasket that goes on the inlet and outlet tubes. I assume its ok to reuse the old one, or maybe cut a new one from some neoprene sheet (i've got a fair amount of self-adhesive 6mm sheet)

I've had some unsuccessful goes at these three

Its these ones. Tried squeezing with pipe grips, gentle twisting with a screwdriver and also trying to open the slot into which they've been pushed through, but no luck at all. I'm afraid they'll snap off then I'll be really snookered

Thanks for that. The ones I'm struggling with are the plastic triangular ones - just afraid I'll break them. I'll rake a proper pic and post up, but this is the box for ref

i've managed to get the centre diverter housing out now, but how do you split the two halves? I cant seem to work out how those clips have clipped in - probably very straightforward but i cant quite see it... thanks Hasan

You'll work your magic on it in no time Matt! Certainly looks a good purchase and look forward to seeing the progress pics

What did you paint them with? I take it they're not pwedercoated? They certainly look good though

Any change when you wiggle the key in the switch? Might just be worth changing it to rule it out anyway. It does point to something loose though, especially as the display seems to disappear when turning the key.

Chris your 'temporary' repair is an exceptional standard! As usual, of course

my switches are from the top: front/rear fogs blank + rear demist seat heaters aircon switches On the RHS of the steering wheel i have the ABS light and headlight switch

Didn't the mk3 switches just go into the place of the original diavia ones below the foglight switches?

Perfect, thanks. If i can get away with leaving the airbox in place and removing just this front portion that will be perfect as i'll also be able to remove and re-felt the flaps. Incidentally, i tried the fan with the outlets disconnected and there were several leaks. I superficially sealed them to test and what a difference it makes! So it seems that the asthmatic fan is not really the problem its more just air leakage and flap seal failure. I'll check again once its all back together. Hasan

Looking good👍

Ive removed the Ive just removed the wiring for this from the harness for the time being. The rod for the thermocouple seems very well stuck into the mastic so I'll just cut that off. Next problem, cant work out how to remove the front section of the ducting behind which i believe the heater matrix sits. I can only find one clip on the side but removing this doesn't seem to loosen anything.

@Cressa interested in the loom to use the Mk3 switches. I've got a set myself and they definitely fit better. Any advice or pics? Thanks Hasan

that pipe goes to the compressor across the front of the engine, Its quite a messy retrofit to be honest, i think the LHD cars were much tidier. The inlet duct also has a motorised flap, which you can see in your picture under the foliage cover - incidentally when the cooling fans come on the flap closes. Yes those are the relays, there should be a loose fitting plastic 'box' that sits on top of them.

Hi Matt, There should also be a dryer next to the aircon condenser at the front, which sits behind the car rad. There should also be a control valve which will be covered in a type of black mastic inside the car, roughly under the glovebox. That's about it. As it's not an easy system to service, I'm still tempted (after hoarding the bits for over 10 years!) to swop in a climatronic setup, although that would take away from the originality Cressa is the guru on maintenance though, he sent me a load of pictures around dismantling the system. Hasan